The 2004 Volvo S40 is a compact executive sedan, built on the P1 platform shared with other manufacturers, and represents Volvo's commitment to safety and Scandinavian design. This model offers a blend of refined engineering and practical utility, making it a competitive choice in its segment. Available with a 2.0-liter inline 4-cylinder engine producing approximately 136 horsepower and 187 Nm of torque, and also offered with 2.4-liter naturally aspirated or 2.5-liter turbocharged engines, the S40 provides a balanced driving experience. Its dimensions, including a length of 4476 mm and a wheelbase of 2635 mm, contribute to a comfortable interior and stable handling. The vehicle also features robust safety systems, including standard Anti-lock Braking System (ABS) and optional traction control, along with comprehensive airbag coverage. This workshop service repair manual provides complete factory-level detail for the 2004 Volvo S40, covering all trim levels. It encompasses a wide array of systems, including engine mechanicals, fuel and exhaust systems, cooling, lubrication, ignition, and engine management. The manual details both manual and automatic transmissions, as well as chassis components such as suspension, steering, and braking systems. Extensive coverage is also given to electrical systems, bodywork, and interior components. Included are essential maintenance procedures, detailed repair instructions for disassembly and reassembly, troubleshooting guides, and diagnostic flowcharts. This comprehensive resource is designed to assist both do-it-yourself enthusiasts and professional mechanics in maintaining and repairing the vehicle effectively. 🏷️ Basic Information Identification Make: Volvo Model: S40 Year: 2004 Chassis Code: P1 Codes Platform: P1 Platform (shared with Mazda 3, Ford Focus Mk2, etc.) 👋 Introduction Market Position Segment: Compact Executive/Premium Compact Sedan Target Audience: Do-it-yourself enthusiasts and professional mechanics Competitive Analysis Key Competitors: BMW 3 Series (E46), Audi A4 (B6), Mercedes-Benz C-Class (W203), Acura TSX, Lexus IS (XE10) Key Features Manual Advantage: Comprehensive, factory-level detail, detailed illustrations, troubleshooting guidance, cost-effective repair solution Vehicle Focus: Designed to empower owners and technicians with the knowledge to maintain and repair the Volvo S40 📋 Manual Details Coverage Areas Geographic Coverage: Global (primarily North American and European specifications) Trim Level Coverage: All trim levels Page Count Estimated Page Count: Hundreds of pages (exact count not specified, but described as 'complete official full factory service repair manual') Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine management, fuel system, exhaust system, cooling system, lubrication system, ignition system Transmission: Manual transmission, automatic transmission (including clutch, gear shifting mechanisms, hydraulics) Chassis: Suspension (front and rear), steering system, braking system (including ABS), wheels and tires Electrical: Body electrical systems, lighting, instrumentation, infotainment, control modules, wiring diagrams, diagnostics Body: Body structure, exterior panels, interior trim, doors, windows, seats, HVAC system Engine Management: Engine control module (ECM) diagnostics, sensor testing, actuator testing, emissions control system Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Repair: Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component repair Diagnostics: Troubleshooting guides, diagnostic procedures for engine, transmission, ABS, SRS, and other control modules Technical Specifications: Torque specifications, clearances, fluid capacities, electrical values Suspension Repair: Strut replacement, shock absorber replacement, bushing replacement, ball joint service, control arm service Technical Depth Depth: Complete disassembly and reassembly instructions, detailed component identification, wiring diagrams, diagnostic flowcharts Wiring Diagrams: Comprehensive electrical wiring diagrams for all systems, including fuse box layouts and component locations. Manual Completeness Coverage: Full factory service and repair coverage, not a condensed version. 📊 Manual Specifications File Format Format: PDF Compatibility: All PC based Windows operating systems and Mac Print Quality Printability: Printable without any restriction (individual pages or entire manual) Binding Type Binding: Digital Download (no physical binding) Paper Type Paper Type: N/A (Digital) Delivery Delivery Method: Instant Download Requirements Software Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code: B4204S3 (2.0L Naturally Aspirated) Engine Type: Inline 4-cylinder, DOHC, 16-valve Displacement: 1948 cc Bore X Stroke: 81.0 mm x 95.2 mm Performance Horsepower: 136 hp @ 6000 rpm (approximate for B4204S3) Torque: 187 Nm @ 4500 rpm (approximate for B4204S3) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Other Engines Available Engines: 2.4L Naturally Aspirated (B5244S2), 2.5L Turbocharged (B5254T2 - T5 models) 🔧 Transmission Standard Standard Transmission: 5-speed Manual (M56H) Optional Optional Transmission: 5-speed Geartronic Automatic (AW55-50SN) Features Manual Clutch Type: Hydraulically actuated, single dry plate Automatic Features: Sequential manual shifting (Geartronic) 📐 Dimensions Exterior Length: 4476 mm Width: 1775 mm Height: 1456 mm Wheelbase: 2635 mm Weights Curb Weight: 1365 kg (approximate for 2.0L) Gross Vehicle Weight Rating: 1900 kg (approximate) Cargo Trunk Volume: 405 liters 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for 2005 model, indicative of 2004 platform) NHTSA Front Impact Passenger: Good (for 2005 model, indicative of 2004 platform) IIHS Front Offset Crashworthiness: Good (for 2005 model, indicative of 2004 platform) Active...